Armature



May 31, 1932; v. G. APPLE ARMA'I'URE Filed may 1, 1950 4 Sheets-Sheet 1 May 31, 1932. v. G APPLE 1,860,978

ARMATURE Filed May 1, 1950 4 Sheets-Sheet 2 V. G. APPLE ARMATURE May 31, 1932.

Filed May 1, 1950 4 Sheets-Sheet 3 V. G. APPLE May 31, 1932.

ARMATURE Filed May 1, 1950 4Sheets-Sheet 4 Patented May 31, 1932 UNITED STATES VINCENT G. APPLE, OF DAYTON, OHIO ARMATURE Application filed May 1,

This invention relates to armatures and particularly to that class comprising a commutator having segments supported by a hub of molded plastic insulation extending between and about them and a winding having a mass of similar insulation extending be tween the turns, and forming a jacket thereabout.

In an armature of this type it is often desirable to employ one kind of plastic insulation to separate and support the commutator segments and another kind to surround and penetrate the winding. This is so because in- I sulation which separates the commutator segments and comes in contact with the brushes is preferably of a nature that will not carbonize under arcing of the brushes, and while such fire resisting materials are obtainable, they are not suitable for penetrating and covering the winding because they may not be brought to a sufiiciently fluid state for that purpose.

On the other hand there are certain insulating materials which are unsuitable for the commutator because they Carbonize readily under the arcing of the brushes yet nevertheless are highly effective for penetrating and covering the winding because they may readily be brought to a highly fluid state, in which state they may be forced into the innermost recesses of the winding.

It is therefore an object of this invention to provide an armature of this type wherein two kinds of insulation, each most suited to its particular purpose, are employed, one kind for the commutator and another kind for the winding.

Other objects and meritorious features'of the invention will be apparent from the detailed description, reference being had to the drawings, wherein- Fig. 1 is a perspective view of a mandrel upon which I assemble the core of my armature.

Fig. is a core assembled on the mandrel Fig. 1 and with the slots lined with sheet insulation preparatory to placing the winding thereon.

Figs. 3 and 4 are sleeves adapted to surround the shank andthe stem respectively 1930. Serial No. 448,940.

of the mandrel Fig. 2 to keep the winding away from the mandrel as it is wound in place on the core.

Fig. 5 shows the winding in place on the core with relatively stifl' leads formed by twisted together ends of the wire composing the coils extending from the winding.

Fig. 6 shows a bar of the stock from. which the commutator segments are made.

Fig. 7 shows a single commutator segment made from the bar Fig. 6.

Fig. 8 shows the wound structure Fig. 5 with a segment Fig. 7 electrically joined to each lead.

Fig. 9 is a perspective view of a tool employed for locating the commutator segments.

Fig. 10 is a spring ring used in connection with the tool Fig. 8. r

Fig. 11 is an axial sectional View taken at 1111 of Fig. 12 through an envelope within which the armature is placed to bring the winding to a definite shape.

Fig. 12 is a transverse section taken at 12-42 of Fig. 11.

Fig. 13 shows the tools of Figs. 1, 3, 1, 9, l0 and 11 assembled with an armature.

Fig. 14 is a transverse section taken at i k-14 of Fig. 13.

Fig. 15 is a section on the line 15-15 of Fig. 13.

Fig. 16 shows the armature after tools 1, 3. 4, 9, 10 and 11 have been removed and the armature placed in a mold with a preformed collar of unmolded insulation of a kind suitable for penetrating the winding and form ing a jacket thereabout.

Fig. 17 is a transverse section taken at 1717 of Fig. 15.

Fig. 18 shows the mold Fig. 16 after the unmolded insulation has been compressed to form a jacket around the entire winding and the winding leads, and around the inner ends of the commutator segments.

Fig. 19 shows the armature placed in a second mold with a preformed collar of unmolded insulation of a kind suitable for filling the spaces between the commutator-segments and making the'commutator core, and a flanged member which is afterward to provide protection to the outer end of the commutator.

Fig. 20 is an end view of the flanged member shown in the mold in Fig. 19.

Fig. 21 shows the armature in the mold after the commutator has been molded.

Fig. 22 shows the shaft with which the armature is to be assembled.

Fig. 23 shows the armature with the mandrel Fig. 1 removed and the shaft Fig. 22 substituted.

Fig. 24 is a section on the line 2424 of Fi 23.

imilar numerals refer to similar parts throughout the several views.

In the drawings the mandrel 26, Fig. 1, comprises a stem 27 having a diameter equal to the central opening in the core laminae and a shank 28 of larger diameter. The shank 28 is flattened on two sides to provide the clutch end 29.

A core 31, Fig. 2, having winding slots 32 separated by teeth 33 is placed on the stem 27, and a single strip 35 of sheet insulation is fitted around the core to extend into and line all of the slots 32. The sleeve 34, Fig. 3 is then placed over the shank 28 of the mandrel at one end of the core and the sleeve 36, Fig. 4 over the stem 27 at the other end of the core, after which the winding may be placed as shown in Fig. 5. The sleeve 34, F 1g. 3, is later withdrawn in order to make space between the back winding head 37, and the shank 28 of the mandrel and the sleeve 36 is withdrawn to make space between the front winding head 38 and the stem 27. The spaces provided by the withdrawal of sleeves 34 and 36 are afterward filled with insulation.

A winding of cotton or other fibrous covered wire is placed on the core, the front head 38 around sleeve 36 and the back head 37 around sleeve 34. Leads 39 extend from the winding for connection to commutator bars as in common practice. But before the winding is placed 011 the core the covering of the wire is preferably saturated and coated with a liquid insulation and partly dried, in order that the pressure incident to the subsequent molding operation will not break down the insulation between adjacent turns, al-

though if desired the winding may be impregnated with liquid insulation and baked after the winding is on the core.

In Fig. 7 I show one of the segments 41 which I use to compose a commutator for my armature. To make these segments I provide wire of trapeziform cross section (see Fig. 6) and cut it into lengths by cutting through the wire at an angle as at 42. Thus for each cut there is produced a segment 41 having one end beveled as at 43 and the other as at 44. A lead slot 46 is then easily cut through the.corner of each segment as shown. Fig. 8 shows the structure after a segment 41 has been joined to each of the leads 39. The

leads are pressed into the lead slots 46 whereupon they may be welded, brazed, soldered orotherwise electrically joined tothe segments. After they are so oined the segments are arranged in proper formation and bound together to compose a commutator.

Fig. 9 is a perspective view of a. tool 47 around which the segments 41 are temporarily assembled in order that they may be more easily entered into the mold. The tool comprises a cylindrical body 48 with an opening at 49 to fit the sleeve 36 and with annular grooves 51 and 52encircling it. A series of integral keys 53 extend from the end of the tool to the groove 51.

When an armature has been wound around the core 31 and sleeves 34 and 36 as in Fig. 5 and has its commutator segments 41 connected to its leads 39 as shown in Fig. 8, the tool 47 is placed over sleeve 36 on the mandrel 26 and the segments 41 are laid around the tool with keys 53 of the tool extending outwardly between the segments (see Figs. 13 and 15). Ring 54, Fig. 10 is now forced over the outside of segments 41.

Inasmuch as the insulationsaturated winding is preferably baked to harden it before the jacket of plastic insulation is molded thereabout, a number of advantages may be gained by holding the winding in a definite shape while it is being hardened, first, because, by drawing the coils and coil heads into circular form concentric with the axis of rotatin and hardening them in this shape, a better mechanical balance may be had and the jacket over them will be of more uniform thickness, and second, because, if the jacket is to be molded around both coil heads at a single operation, passages through which the plastic insulation may pass from one end of the core to the other are preferably provided. buch passages are readily made by keeping vacant a portion 56 of each winding slot 32 at 1ts outer edge. (See Figs. 8 and The envelope 57, Figs. 11 and 12, is made in two halves 58 and at), held together by nut 61 and has cupped ends and 63, an'opening 64 for sleeve 34 to extend through, an

opening 66 to clear the cylindrical row of segments 41. and a series of inwardly extending keys 67 to enter the outer portions 56 of slots 32 to press the coils inwardly and compact them more closely into the bottoms of the slots and thereby leave spaces 56 at the outer ends of the slots after the coils are hardened. Q

Fig. 13 shows the armature structure assembled with the tools shown in Figs. 1. 3. 4, 9, 10 and 11, ready to be baked to harden the winding, and it will be observed that the coil heads are closely surrounded and held in definite shape by the envelope 57. By also referring to Fig. 14 it will be seen that the keys 67 keep the coils pressed inward. so that when the coils are hardened and the envelope ISO is removed the outer portions 56 of the slots will be vacant.

Afterbaking the assembly Fig. 13 for a suflicient length of time to harden the wind- Figs. 3, 4, 9, and 11 are reings the tools I the mandrel Fig. 1 in place.

moved, leaving The structure is then entered in the mold 68,

Fig. 16,. within which the jacket for the 1 windings is formed.

' The mold 68 shown at two stages of its operation in Figs. 16 and 18 has a cylindrical body 69 hollowed out at thelower end at71 somewhat of the contour but slightly larger than the front head 38, at the ripper end at 72 to fit the plunger 73 and intermediate at 74 toireceive the core 31 which rests on the shoulder 76. The subbase 77 has a hub 78 of the same contour but smaller than the end of sleeve 36 so that space 79 is left between the hub and the winding head. Openings 80 separated by spacers 81 (see Fig. 17) receive segments 41, and a central opening 82 receives the stem 27 of mandrel 26. The base f collar 104 is then brought to its most fluid than the back winding head 37 and has a central opening 88 to slidably fit over shank 28 of mandrel 26. O

To operate the mold 68 the armature is placed therein as shown together with the preformed collar 89 of unmolded plastic insulation. This insulation is preferably of a kind which may be brought to a high degree of' fluidity at the instant it is forced between and about the turns of the winding not only so it may penetrate'the innermost recesses of the turns but so it will be pressed about the winding hydraulically, that is, so that the pressure incident to molding the fluid will be applied equally in all directions. This is importantinasmuch as insulation which may by pushing be brought to a semi-plastic state only would crush the coils when an attempt was made to force it into and around them.

Fig. 18 shows the mold 68 after the jacket 91 of insulation has bee-n forced into and about the back winding head 37, downwardly through the openings 56 formed by'the keys 67 ofenvelope 57 into and about the front winding head 38 and around the ends of the segments 41. Itwill be seen that the ends of the commutator segments 41 extend into jacket 91 sufficiently to support them in spaced apart relation when the mold is afterward removed.

After the jacket 90 is sufficiently hard, the base 83 is first removed then the segments 41 are pushed from the openings of the subbase 77,

then the armature together with plunger 73 is pushed from the body 69, then on shank 28 the armature is removedfrom plunger 73.

' 20) and The mandrel 26' is left inthe armaturefor the subsequent 'op;

eration of molding a core of fire resisting insulation within and between the segments.

Themold 92 shownintwo stages of its operation in Figs.-19 and 21 has a base 93, a body 94 and a plunger 96. The base 93 is hollowed out at 97 to receive the back winding head 37 with its portion of jacket 91, the body,is bored at the lower end at 98 to receive the" core 31 and at 99'to receive the-front windinghead 38 and its part of the jacket-91, the remaining part of the body having the central opening 101 into which the plunger 96 is slidably fitted. Base93 has a central opening 102 for shank 28 and plunger 96 has a central opening 103 for stem 27.

In operationthe armature with its molded jacket of insulation is placed in mold 92 together with a preformed collar 104 of fire resisting insulation. An end protecting flange 106 with perforations 107 (see Fig. a tubular hub 108 .is placed over collar 104 and the plunger 96is slightly entered into opening 101. The preformed state and the plunger 96 pressed downward to its position shown in Fig. 21, forming the commutator core 111 which extends into the opening 112 within winding head 38, into perforation 107 and between and about the spaced apart segments 41 to form the commutator. After the core 111 is sufficiently hard the armature is removed from mold 92 and the mandrel 26 from the armature.

When the mandrel 26 is removed from the armature it will be seen that the clutch end 29 has formed a depression 113 in the insulation jacket 91. (See Figs. 23 and 24.) This depression is utilized to provide driving relation between the armature and its shaft. i

The armature shaft 114 has a collar 116 near its middle which is flattened to correspond with the clutch end 29 of mandrel 26. Shaft 114 is held in place by nut 1 17. The cylindrical opening 118 left when shank 28 is withdrawn may be utilized for one of the bearing hubs of the armature.

From the foregoing description. and from ture of this invention consists of holding the segments at their ends beyond the brush track, by the insulation mass forming acket 91, to keep them properly spaced apart until the fire resisting insulation may be forced between them; Where it is desirable to have the same insulation mass which forms the commutator core extend also outwardly between the segments to the brush track, that is, where no undercut commutator is desired, the method herein described is adaptable, since it provides a means to hold the segmentsin spaced apart relation until the'desired insulation may be forced, between them, whether this desired insulation differs in its nature from that forming the jacket over the winding or not.

In my copending application Serial No. 4'T2,679 filed August 2nd, 1930, I show and claim the tools herein shown in Figs. 1 and 3 and the tool shown in Fig. 11, I therefore do not herein claim these tools.

In my copending application Serial No. 436,149, filed March 15th, 1930, I show and claim an armature having a removable shaft such as I herein show in Fig. 22 in which a flattened driving collar on the shaft engages corresponding driving pockets molded in the body of insulation such as I herein show in Fig. 24. I therefore do not herein claim this feature.

In my copending application Serial No. 435,485, filed March 13th, 1930, I show and claim an armature having an end plate such as I herein show in Fig. 20, which end plate is held to the body of insulation solely by the insulation itself. I therefore do not herein claim an armature having this feature.

In my copending application Serial No.

363.702, filed May 16th, 1929, I show and claim an armature as well as a method of making it in which segments as herein shown in Fig. 7 are joined to leads as herein shown in Fig. 8 and afterwards formed into a commutator by molding a core ofinsulation about them. I therefore do not herein claim this feature or the method of making an armature having this feature. 1 Claims in the present application are confined to a specific structure in which the core of the commutator is composed of insulation of a different nature from that forming the jacket of the winding and method whereby such a structure may be produced.

Having described my invention, I claim:

1.'A method of making a commutator, which consists of holding the required number of segments in proper spaced apart relation by one end, molding insulation between themat the other end, hardening saidinsulation, then molding insulation between the segments at the first said end;

2. A method of making a. commutator, which consists of holding the required number of segments in cylindrical spaced apart relation by one end, molding insulation between the other ends, hardening said insulation then molding insulation between the remaining portion of the segments.

3. A method of making a commutator,

which consists of holding the segments inspaced apart relation by metallic spacers extending between them. at one end, molding insulation between the segments at the free end, hardening said insulation, removing said metallic spacers then molding insulation into the space vacated by said metallic spacers.

4. Steps in the method of making an armature, which consists of winding the armature, attaching individual commutator segments to the winding at suitable intervals, holding the segments in proper spaced apart relation by their outer ends, molding insulation around their inner ends while so held, hardening said insulation, then molding insulation between their outer ends.

5. Steps in the method of making an armature, which consists of winding the armature, attaching individual commutator segments to the winding at suitable intervals, holding the segments in proper spaced apart relation by their outer ends, molding an integral mass of insulation around the inner ends of the sulation into the spaces vacated by the said metallic spacing means.

7. An armature comprising a Winding, individual commutator segments attached at proper intervals to said winding, an integral mass of penetrative insulation extending into and around said winding and around the inner ends of said segments and separating spacers of fire resisting insulation between the segments at their outer ends.

8. An armature comprising a winding, in dividual commutator segments attached at appropriate intervals to said windingand spaced apart in a cylindrical row, an integral mass of penetrative insulation extending into and around the winding and around the inner ends of the said segments, and an integral core of fire resisting insulation within said cylindrical row of segments and extending outwardly between them.

'9. In an armature, a winding head extending in the form of a ring from the end of the core, individual commutator segments attached to leads emanating at intervals from said ring and spaced apart in the form of a cylinder, an integral mass of penetrative insulation surrounding and covering said ring and surrounding the inner ends of the segments, and an integraLcore of fire resisting insulation within said cylinder, extending.

outwardly between the outer ends of the segments and axially within said ring.

10. In an armature, a winding head extending in the form of a ring from the end of the core, individual commutator segments attached to leads emanating at intervals from said ring and spaced apart in the form of a cylinder, an inte ral mass of penetrative insulation surroun ing and covering said ring 1 and surrounding the inner ends of the segments, an integral core of fire resisting insulation within said cylinder extending outwardly between the outer ends of the segments and axially in the form of a hub into 15 said ring, and a metal protecting flange at the outer end of said core having a tubular hub extending axially into the first said hub. 11. A method of making a commutator, which consists of holding the requisite num- 29 her of segments in spaced apart cylindrical formation by one end only, molding a body of insulation between and about the other ends, hardening said body of insulation, then molding a second body of insulation between 25 and about the first held ends while the other ends are being held solely by the first said' body. y

In testimony whereof I afiix my signature.

so VINCENT G. APPLE. 

